Circular warp knitting machine



Aug. 4, 1970 R. E.4 MERRITT ETAI- cIRcULAR WAR?" KNITTING MACHINE l0Sheets-Sheet l Filed Oct. 18, 1967 Robe-2T E. MesasznTT/Z ATTORNEYS Aug.4, 1970 R. E. MERRITT ET AL' CIRCULAR WARP'KNITTING MACHINE l0Sheets-Sheet 2 Filed Oct. 18. 1967 TN N mno .MR r O v2 w W. E M A M.EJMI T5 Wd R.. ET if@ CnD Nm 5T w o mw; P VQ k. ,fr +90@ i? mju o :Il @Omo. Ow n v Nb v m` wg Aug- 4, 1970 R. E. MERRITT ETAL 3,522,715

CIRCULAR WARP KNITTING MACHINE Filed Oct. 18. 1967 10 Sheets-Sheet 5ATTORNEYS Aug. 4, 1970 R. E. MERRITT ET AL 3,522,715

CIRCULAR WARP KNITTING MACHINE 10 Sheets-Sheet L Fld Oct. 18. 1967' .L,ya 1 W w Vw@ ATTORNEYS Aug. 4, 1970 R. E. MERRITT ET AL 3,522,715

CIRCULAR WAR? KNITTING MACHINE Filed oct. 18'. 19s? 1o sheets-sheet sATTGRNEYS Aug. 4, 1970 R. E. MERRl'r-r ET Al- 3,522,715

CIRCULAR WARP KNITTING MACHINE 10 Sheets-Sheet 6 Filed Oct. 18, 1967 l45o y), d

ATTORNEYS Augy4, 1970 R. E. MERRITT ETAI- CIRCULAR WAR? "KNITTING MCHINEl0 Sheets-Sheet 7 Filed Oct. 18. 1967 INVENTORS: 22H-Tand l .-12 RQBERTE: ME

Cmns *T SMMONS www4/@MMM ATTORNEYS R. E. MERRITT ETAL CIRCULARWARFKNITTING MACHINE Aug. 4, 1970 l0 Sheets-Sheet 8 Filed Oct. 18. 1967INVENTORSI EQBEET E. Measzm and Owens .T SIMMONS BYMl/{jq/sm ATTORNEYSAug. 4, 1970 R. E. MERRITT ET AL 3,522,715

CIRCULAR "ARP KNITTING MACHINE l0 Sheets-Sheet 9 Filed Oct. 18. 1967 TRmy NM M d IEdSM TMI Q S E Il I: (if: l l i l Z BYM.

ATTORNEYS Aug. 4, 1970 R. E. MERRITT ETAI- 3,522,715

CIRCULAR WARPKNITTINC MACHINE 4Filed oct. 18. 19s? 1o sheets-sheet 1oINVENTORS RQBERT E'. MEEExTTand ATTORNEYS United States Patent ABSTRACTOF THE DISCLOSURE Sets of warp yarns are selectively guided to acircular series of latch needles as they are simultaneously raised andlowered to rapidly form an open lace type tubular fabric havingperiodically interconnected stitch chains. The rate of yarn feed andfabric taken up is varied to change the size of the stitches -beingformed and to thereby fashion the tube `as it is knit. Pattern controlmeans is provided for transversely cutting the seamless tubular fabricafter a predetermined number of courses have been knit to formindividual stocking `blanks and the like. Means is also provided forlongitudinally slitting the fabric adjacent the lateral cut to formblanks suitable for use in the formation of full length tights and thelike.

This invention relates generally to circular Warp knit fabrics, acircular warp knitting machine and a method of knitting such fabric andmore particularly to such a machine and method wherein a wide variety ofdifferent types of open lace, 'Raschel type, Warp knit tubular fabricsof particularly high quality may lbe produced in a rapid and economicalmanner.

Warp knitting machines are generally flat-bed machines provided with aflat needle bed and a plurality of guide bars for directing individualyarns to different needles. It is also known to provide two needle bedson such machines of the Raschel type to thereby permit the knitting oftubular fabric on such machines.

Machines of this latter type are particularly useful in making open lacetubular stockings or so-called ishnet stockings characterized byperiodically interconnected stitch chains. For example, such two bed-Raschel machines may be set up to knit thirty or more tubessimultaneously across the width of the bed at a speed of about 250courses per minute. A disadvantage of these machines is that theyrepresent a rather largeinvestment for a mill owner and that it israther difficult to obtain uniform stitch size; particularly where thefabric from the front and back needle bars are connected together atopposite sides. These connector stitch chains at opposite sides includelooser or longer stitches which form fault lines extending down opposedsides of the tubular fabric.

The basic concept of circularizing the needle bed of a warp typeknitting machine has been known for many years and has been employed inhighly simplified machines designed to knit incandescent gas mantles forgas lamps. However, the adaptation of this concept to a hosiery machinefor knitting open lace-type fabric has not heretofore been known.However, we have found that such concept can Ibe adapted with certainmodifications into a hosiery machine with the surprising result thatopen lace type stocking blanks free from fault lines can be knit thereonat rates of speed of up to 1800 or more courses per minute.

With the foregoing in mind, it ils an object of the present invention toprovide an open lace type tubular fabric of particularly high qualitywhich is knit on a circular warp knitting machine capable of producing awide variety of different types of interconnected stitch chain paticeterns and at a very rapid rate of speed, such as up to 1800 or morecourses per minute.

It is a further object of the present invention to provider a positivetake-up means for withdrawing the knit tube from the circular warpknitting machine at a predetermined rate and positive yarn feeding meansfor feeding. Athe yarns to the needles at a predetermined rate relative4to the fabric take-up. Common drive means is provided for the take-upand the yarn feed and the speed of the common drive means determines thesize of the stitch loop being knit. The machine includes a lvariablespeed drive which controls the common drive means for the take-up andyarn feed so that the size of the stitch loop may be varied during theknitting of a single stocking blank to thereby provide fashioning of theblank.

In accordance with another feature of this invention, the circular warpknitting machine` may be provided with severing means supported totransversely cut the knit tube at selected intervals and form stockingblanks of the desired length. And further, automatic means may beincorporated on the machine to longitudinally cut or slit the fabricfrom a point adjacent the transverse cut line so that a leotard ortights-type garment blank may 'be formed on the machine. In forminggarments therefrom the slit inner portions of adjacent pairs of stockingblanks maybe connected together, either directly or by means of anadditional crotch piece.

Some of the objects of the invention having been stated, other objectswill lappear as the description proceeds when taken in connection withthe accompanying drawings, in which L FIG. 1 is a side elevation of thecircular warp knitting machine of the present invention and showing onlythe forward portion of the yarn creel therefor;

IFIG. 2 is an enlarged side elevation of the opposite side of thecentral portion of the knitting machine shown in FIG. 1;

FIG. 3 is a vertical sectional View through the positive yarn feedingmeans and illustrating the manner in which the yarns are wrapped aroundthe positive feed drive shaft as they are withdrawn from the yarn creeland moved toward the knitting needles;

FIG. 4 is a plan view of the knitting machine;

FIG. 5 is a front elevation of the central portion of the machine,looking inwardly from right to left in FIG. 2; FIG. 6 is an enlargedfragmentary vertical sectional view taken substantially along the line 66 in FIG. 5 and illustrating the fabric cutting land .slitting means;

FIG. 7 is a fragmentary isometric view of a portion of the knittingmachine, looking inwardly at the needle cylinder from the left-handfront corner of the machine;

FIG. 8 is an isometric sectional view through the needle cylinder andthe yarn guide rings and showing a portion of one type of open lacefabric produced on the machine;

FIG. 9 is Ia vertical sectional view illustrating the manner in whichthe pattern wheels are supported for adjustment and easy removal on thedrive shaft therefor;

FIG. 10 is an enlarged vertical sectional view through the broken yarndetecting stop motion device of the knittingv machine, shown in theupper portion of FIG. 1;

FIG. 11 is a view of a portion of the creel taken substantially alongthe line 11-11.in FIG. 1 and illustrating the manner in 'which the yarnsupply cones are supported and how pairs of cones may be tied togetherto provide continuous operation;

FIG. 12 is an enlarged sectional plan view taken substantially along theline 12-12 in FIG. 11 and illustrating the manner in which the yarns arewithdrawn from the yarn cones and directed forwardly to the knittingmachine by the creel;

FIG. 13 is an isometric view of a stocking :blank of the type `which isutilized to for-m tights or panty type garments and illustrating thetapered fashioning of the blank and the longitudinal slit which may beprovided at the upper end;

FIG. 14 is a greatly enlarged, somewhat schematic representation of onetype of open lace pattern fabric which may be knit, being that portionof the blank enclosed by the dotted rectangle 14 in FIG. 13;

FIG. 15 isa point-paper schematic diagram illustrating the manner inwhich the yarns are fed to the needles in knitting one repeat of thefabric shown in FIG. 14;

FIGS. 16-23 illustrate the various positions assumed by the yarn guidesduring `the simultaneous up and down movements of the needles to showthe manner in which the yarns are fed to the needles;

FIG. 24 is an enlarged view of a modied type of open lace pattern fabricwhich may be knit;

FIG. 25 is a point-paper schematic diagram of the manner in which theyarns are fed to the needles in knitting one repeat of the fabric shownin FIG. 24;

FIG. 26 is an enlarged View of another modified type of open lacepattern fabric which may be knit; and

FIG. 27 is a point-paper schematic diagram of the manner in which theyarns are fed to the needles in knitting one repeat of the fabric shownin FIG. 26.

The machine includes a lower stand which supports the knitting machineframe 11. The frame 11 is preferraibly cast in one solid integral pieceand is suitably attached to the stand 10. As shown in FIG. 5, the frame11 is substantially rectangular in cross section and is preferably openat opposite ends.

An electric drive motor 12 is supported on the lower portion of thestand 10 (FIG. 1) and includes a drive pulley which imparts motion to adrive `belt 13, engaging a drive pulley 14 which is fixed on one end ofa main drive shaft 15. The main drive shaft 15 extends through and isrotatably supported in opposite sidewalls of the frame 11 and one endmay be provided with a suitable hand wheel, shown in dash-dot lines at16 in FIGS. 4 and 5.

The opposite end of the main drive shaft 15 is provided with a drivepulley 17 (FIG. 2) which is engaged by a drive belt 18 to impartrotation to a drive pulley 19. The pulley 19 is fixed adjacent one endof a transverse drive shaft 20 (FIG. 4) which is rotatably supported inthe frame 11. A drive pulley 21 is xed on the opposite end of the shaft20 (FIG. 1) and is engaged lby a drive belt 22 which extends upwardlyand around a drive pulley 23. The belt 22 is maintained in a tightcondition by `a belt tightener roller 24 which is rotatably supported onone end of an adjustable bracket 25 on the outside portion of the frame11 (FIG. l).

The pulley 23 is xed on one end of a cam shaft 26 (FIG. 4) which issupported for rotation in sutable bearing blocks 27, xed on the machineframe 11. The cam shaft 26 is adapted to support pattern means orpattern chains, to be presently described, and imparts rotation theretoin timed relationship to the operation of the machine.

The lower end of a slotted needle cylinder 30 is supported in a fixed,non-rotating position on an upper transverse portion of the machineframe 11 (FIGS. 6 and 7) and has latch needles 31 supported for verticalmovement in the slots therein (FIG. 8). The needles 31 are preferablyheld in the slots by a removable spring band 32 which extends around theouter periphery of the shank portions of the needles 31 (FIG. 7).

The needles 31 are provided with lower operating butt portions 33 whichdiffer from the usual needle butts in that they are rounded along thelower inner and outer portions, as shown at 33a in FIG. 8. This roundedlower portion 33a is provided to facilitate removal and replacement ofthe needles 31 in the needle cylinder 30. The needles 31 aresimultaneously raised and lowered by a needle operating ring 34 whichsurrounds the needle cylinder 30 (FIG. 8) and includes a butt engaginggroove 34a in which the butts 33 of the needles 31 are disposed. Theupper inner portion of the ring 34 is beveled so that a needle may beeasily replaced by removing the spring band 32 and outwardly rocking theupper end of the needle to be replaced. The tip of the butt 33 of thenew needle may then be placed in the slot 34a and the upper end rockedinwardly into the vertical position so that the needle is securelyconnected to the ring 34.

As best shown in FIG. 5, opposite sides of the needle operating ring 34are suitably secured to the upper ends of vertically disposed operatingrods 35, 36. The upper portions of the rods 35, 36 are supported forvertical sliding movement in the upper horizontal portion of the frame11 and the lower portions are supported for vertical sliding movement onthe inner ends of guide support arms 37, 38 which are preferably formedintegral with the inner surfaces of the frame 11. The lower ends of theoperating rods 35, 36 are suitably secured to the outwardly extendingportions of a yoke 40 that is adjustably secured to the upper end of anaccentric 41. The eccentric 41 is fixed on the main shaft 15 andcounterweights 42 are preferably provided on opposite sides thereof tobalance the motion of the eccentric 41 as it is rotated at high speedsto thereby raise and lower the needles 31 in the needle cylinder 30.

As the tubular fabric, indicated at T in FIG. 6, is produced by theneedles 31, in a manner to be presently described, it is drawndownwardly and flattened as it passes beneath an idler roller 45. Thefabric T is drawn forwardly by a pair of fluted take-up rolls 46, 47which are driven at a predetermined rate and in a manner to be presentlydescribed.

Means for periodically slitting the tubular fabric in a longitudinaldirection is broadly indicated at 50 and means for transversely cuttingthe tubular fabric is broadly indicated at 51 in FIG. 6. The slittingmeans 50 is disposed between the roller 45 and take-up rolls 46, 47 andthe cutting means 51 is disposed closely adjacent the output side of thetake-up rolls 46, 47 and will be later described in detail.

A drive coupling sleeve 53 connects one end of the drive shaft 20 (FIG.4) to the input shaft 54 of a variable speed drive mechanism 55. Thevariable speed drive 55 is suitably supported on the stand 10 and has anoutput shaft 56, on which a drive pulley 57 is supported. A belt 58drivingly connects the drive pulley 57 to a drive pulley 59 which isfixed on one end of a positive yarn feed shaft 60. Opposite end portionsof the shaft 60 are rotatably supported in bearings 61, 62 which are xedon the frame 11.

The medial portion of the shaft 60 is provided with closely spaced,V-shaped drive grooves which engage the warp yarns W as they are fed tothe machine and Withdrawn from a yarn supply creel, to be presentlydescribed. Guide support arms 64 are fixed at their inner ends on thebearings 61, 62 (FIG. 4) and their outer ends are bent upwardly andsupport opposite ends 0f yarn guide rods 65, 66 (FIG. 3). Respectivesprings 67, 68 surround the guide rods 65, 66 and provide suitablespacing means for the warp yarns W as they approach and leave the yarnfeed roll 60. The warp yarns W extend from the guide rod to the guiderod 66 (FIG. 3) and are wrapped one time about the grooved medialportion of the feed roll 60 to provide a positive feed to the yarns W.

A sprocket 70 (FIG. 4) is fixed on one end of the shaft 60 and isengaged by a chain 71 which imparts rotation to a sprocket 72 which is,in turn, fixed on one end of a front take-up shaft 73. The front take-upshaft 73 is supported for rotation in take-bearing stands 74, 75 (FIG.4) and the upper take-up roll 46 (FIG. 6) is xed on the medial portionof the take-up shaft 73. Suitable meshing gears, not shown, in a gearhousing 76 (FIG. 7) impart driving rotation to the lower feed roll 47and suitable spring means, not shown, in the housings 74, 75 urge thelower take-up roll 47 into engagement with the upper take-up roll 46 sothat the tubular fabric T is positively drawn therethrough in a attenedcondition and at a predetermined speed.

The take-up speed of the fabric and the feeding speed of the yarn may bevaried, in a manner to be presently described, by the variable speeddevice 55. When the fabric take-up speed and the yarn feed speed arechanged, relative to the speed at which the needles 31 are raised andlowered to form courses of stitches, the size of the stitch loops ischarged so that the fabric tube is fashioned to vary the diameter of thetube being knit.

A pattern chain sprocket 80 is xed on the take-up shaft 73 and a patternchain 81 is supported thereon for movement in timed relationship tooperation of the machine. It is preferred that the pattern chain 81 makeone cornplete revolution as each article blank is knit. The lowerportion of the pattern chain 81 is directed around an idler sprocket 82which is, in turn, supported on an adjustment arm 83. In the Ipresentinstance, the pattern chain 81 is adapted to control the operation ofthe slitting means 50 (FIG. 6), the cutting means 51, and the positionof a speed change control arm 84 on the variable speed device 55 (FIG.2).

The speed change control arm 84 is normally drawn forwardly to arelatively fast speed position by a tension spring 85 (FIGS. 2 and 4).The rear end of a control link 86 is connected to the control arm 84 andthe forward end is suitably connected to one end of a control lever 87(FIG. 4). The control lever 87 is pivotally supported intermediate `itsends as at 88 and its other end is provided with a roller 89 which rideson the lefthand side` of the pattern chain 81 and aginst suitablepattern lugs 90.

The pattern chain 81 is shown in FIG. 2 in the position it occupies atthe start of the knitting of a stocking blank with the roller 89 of thecontrol lever 87 (FIG. 4) on a very low pattern lug 90. As the patternchain 81 moves in a counterclockwise direction in FIG. 2, the lugs 90progressively increase in height so that the control link 86 moves thecontrol arm 84 rearwardly to gradually reduce the speed of the yarn feedshaft 60 and the take-up rolls 46, 47 so that smaller stitches areformed. As the size of the stitch loop is decreased, the diameter of thetubular fabric is reduced to fashion the blank, in the mannerillustrated in FIG. 13. When the knitting of one blank is completed, theroller 89 moves from a high lug 90 to a loW lug and the control arm 84is shifted back to the fast speed position so that the machine againforms long, loose or large stitches, at the start of the knitting of thenext stocking blank.

As the tubular knit fabric T passes from the idler roller 45 (FIG. 6) tothe take-up rolls 46, 47, it moves around an elongate flattened guidemember 92 which is provided with a groove or slot in the medial portionof its lower surface. The slot is adapted to receive the upper corner ofa blade 93 to, at times, form a longitudinal slit in the tubular fabricT. The blade 93 is preferably in the form of a safety razor blade and issuitably supported in one end of an operating arm 94. The other end ofthe operating arrn 94 is supported on one end of a stub shaft 95 Whichextends through the sidewall of the frame 11 and has the lower end of anoperating arm 96 fixed on the other end thereof.

The upper end of the operating arm 96 is provided with a follower roll97 which rides against the right-hand race of the chain links of thepattern chain 81. A tension spring 98 resiliently maintains the followerroll 97 in engagement with the pattern chain 81 (FIG. 6) and normallyholds the blade 93 in the solid line position and out of engagement withthe tubular fabric T. As the follower roll 97 is engaged by raised camlugs 99 (FIG. 6) the blade 93 is moved to the dotted line position andinto the groove in the guide 92 so that a longitudinal slit is cut inthe lower side of the flattened tubular fabric as it is drawn over theguide 92.

This longitudinal slit is indicated at S in FIG. 13 and is preferablyformed at the proper time to cooperate with a transverse cut across thetubular fabric. To form the transverse cut, the tubular fabric T isguided over a fixed blade portion 100 (FIG. 6) as it leaves the take-uprolls 46, 47. A movable blade 101 is pivotally supported at one end on`the fixed blade 100 (FIG. 4) and its opposite end is suitably connectedto a solenoid 102, which is operable to at times move the blade 101across the fixed blade 100 and transversely cut the tubular fabric T.The movable blade 101 is normally urged to the outer inoperativeposition by a tension spring 103, one end of which is connected to themovable blade 101 and the other end of which is suitably supported on abracket 104 lxed to the machine frame 11.

The operation of the solenoid 102 and the movable blade 101 iscontrolled by means of a switch 105 (FIG. 1), supported on the chainsupport arm 83 and positioned to be engaged by suitable pattern lugs,not shown, on the extreme left-hand portion of the pattern chain 81which extend outwardly from the side thereof. When it is desired -totransversely cut the tubular fabric T, the switch 105 is closed at theproper time by a pattern lug on the pattern chain 81 to energize thesolenoid 102 and pull the blade 101 across and in engagement with thefixed blade 100 to cut the tubular fabric T. As the plunger of thesolenoid 102 nears. the end of its inward stroke (FIG. 4), theelectrical circuit to the solenoid 102 is broken by a breaker switch 106suitably sup-y ported on the solenoid 102 and the blade 101 isimmediately returned to the open position by the spring 103. Recyclingof the solenoid 102 is prevented by a relay not shown, until the patternlug passes the switch 105.

The warp yarns W are withdrawn from a creel, broadly indicated at 110,which is supported on the floor, independently of and behind theknitting machine. Only the front portion of the creel is shown in FIGS.1 and 11, 12, it being understood that a separate warp yarn is providedfor each needle in the needle cylinder and in the present instance themachine is provided with 84 needles. The creel 110 includes a verticalsupport post 111 which has horizontally disposed support bars 112connected thereto (FIG. 12) which support guide rods 113 havingseparator springs 114 supported thereon. From the support bars 112, theyarns are guided beneath a guide rod 115 (FIGS. l and 4) which issuitably supported at opposite ends in spaced relationship behind themachine frame 11 and is provided with a separator spring 116 whichmaintains the Warp yarns W in spaced alignrnent as they are directedtoward the machine.

The creel 110 also includes horizontally disposed yarn support bars 118which are provided with outwardly and upwardly diverging yarn supportstuds 119 (FIG. l1) adapted to support yarn supply packages P which arepreferably wound on paper cones or tubes. Each warp yarn W is withdrawnfrom its corresponding supply package P and outwardly around a tensionthread guide, such as illustrated at 120 in FIG. 12. The thread tensiondevices 120 are supported on horizontal frame members 121 and the warpyarns W from the rear supply packages, not shown, are guided forwardlyto engage the guide rods 113 and then converge to pass beneath the guiderod 115.

The yarns W then are directed upwardly, over the guide rod 65, wrap thepositive feed roll 60, beneath the guide rod 66, and then upwardly to astop motion device spaced above the knitting machine and indicatedbroadly at 125 (FIGS. l and 10). As shown in FIG. l0, the warp yarns Ware directed upwardly over a guide rod 126, which is provided with aseparator spring 127 and then over a pair of spaced guide rods 128, 129.Each warp yarn W supports a drop wire 130 which is maintained in theposition shown in FIG. l0 and out of engagement with an electricalcontact element 131 as long as the drop wire 130 is supported by thewarp yarn W. Should one of the warp yarns break or become excessivelyslack, the drop wire 130 will drop down and engage 7 the contact element131 to thereby stop the electric drive motor 12 and knitting machine.

As the warp yarns W leave the guide rod 129, they are divided into twogroups W-1 and W-2 and pass over respective guide rods 132, 133 whichare provided with suitable separator springs 134, 135. The stop rnotiondevice 125 is supported in spaced relation above the knitting machine(FIG. l) on the upper end of a vertical support post 137, the lower endof which is connected to the stand of the machine.

The groups or sets of warp yarns W-l and W-2 are directed downwardlyfrom the stop motion device and to yarn guide ring means which includesat least an upper guide ring (FIG. 8) and a lower or bottom guide ring142. The inner edge of the guide ring 140 is provided with vertical yarnguide holes 143 which correspond in number and spacing with the needles31 in the needle cylinder 30. The holes 143 are spaced closely adjacentthe inner peripheral edge of the guide ring 140 and, as shown in FIG. 8,the yarns W-1 are threaded through every other hole 143 in what will bereferred to as a one in, one out arrangement. The outer peripheral edgeof the ring 140 is beveled on both the upper and lower sides, asindicated at 144 to provide means to oscillatably support the ring 140in a plurality of support rollers 146. Three rollers 146 are shown inFIG. 7 and they are each provided with V-shaped grooves to mate with theouter peripheral edge of the upper guide ring 140. The rollers 146 aresupported on the upper end portion of support posts 147 by means ofadjustment brackets 148 and the lower ends of the posts 147 are xed inthe machine frame 11.

The lower yarn guide ring 142 is provided with an inner upstanding edgeportion 150 and horizontal yarn guide holes 151 which correspond innumber and spac- Y ing with the needles 31 in the needle cylinder 30.The lower portion of the lower guide ring 142 is tapered at its innerperipheral edge, as at 152 (FIG. 8), and serves as a latch opening guardwhen the needles 31 are raised during each course of knitting, in amanner to be presently described.

The set of warp yarns W-2 is split into three groups and directeddownwardly and beneath separator guide springs 154 (FIG. 7) which aresupported at opposite ends on the upper surface of the lower guide ring142. The yarns W-2 are directed downwardly and pass between the coils ofthe spring 154 (FIG. 8) and move along a horizontal path as they move toand through the horizontally disposed yarn guide holes 151. As the yarnsW-2 pass downwardly from the horizontally disposed yarn guide holes 151and to the needles 31, they are positioned outside of the yarns W-1substantially as shown in FIG. 8. In order to properly feed the sets ofyarns W-1 and W-2 to the needles 31, it is necessary to oscillate theyarn guide rings 140, 142 in the proper timed relationship, relative tothe raising and lowering of the cylinder needles 31 in order to producethe desired type of pattern in a tubular fabric.

The outer peripheral edge of the lower guide ring 142 is beveled, as at155 (FIG. 8) and is supported for oscillation in rollers 156 havingmating grooves therein (FIG. 7). Three rollers 156 are shown in FIG. 7and they are each supported in a bracket 157 which is adjustably securedto the upper portion of the support post 147. Oscillationsare impartedto the upper guide ring 140 and the lower guide ring 142 by means ofrespective control links 160, 162, the forward ends of which aresuitably connected to the respective rings 140, 142 (FIG. 7) and therear ends of which are connected to the upper ends of bell crank arms163, 164 which are fixed at their lower ends on respective stub shafts165, 166. The stub shafts 165, 166 are supported in bearing blocks 167,168 and the lower ends of corresponding bell crank levers 170, 171 areconnected to the stub shafts 165, 166. The upper ends of levers 170, 171are provided with respective cam rollers 170a, 171:1 which areresiliently urged into engagement with pattern means, illustrated asrespective pattern cam wheels 173, 174. The rollers 17051, 171a areresiliently urged against the cam wheels 173, 174 by tension springs 175(FIG. 2).

Thus, the sinuous shape of the peripheral surface of the cam wheels 173,174 determines the timing 'and amount of movement or oscillationimparted to the respective upper and lower yarn guide rings 140, 142 tothereby control the manner in which the yarns are fed to the hooks ofthe cylinder needles 31. While pattern cam wheels are illustrated at 173and 174 for controlling the oscillation of the yarn guide rings 140,142, it is to be understood that pattern chains forming a sinuous camsurface could be utilized in place of the cam wheels 173, 174. Thepattern chains could extend down inside of the frame 11 and, if ofsufficient length, could extend out the rear of the frame 11 and downbeneath the machine, if necessary.

In order to provide adjustment and easy removal, the pattern Wheels 173,174 are supported on the pattern shaft 26 (FIG. 4) by means ofadjustment locking sleeves, such as illustrated at 176 in FIG. 9. Thesleeve 176 is split at its inner end and has a long gradual taper whichfits against the inwardly tapered inner peripheral surface of a hub 177to which the pattern cam wheel is suitably attached. Screws 178 areutilized to draw the tapered hub 177 onto the sleeve 176 and cause theinner split portion of the sleeve 176 to tighten against the patternshaft 26.

METHOD OF OPERATION A wide variety of different patterns may be producedwith the machine of the present invention. One preferred type of fabricpattern to be described will be referred to as a honeycomb pattern. Aportion of this pattern is illustrated as it is being drawn down theneedle cylinder 30 in FIG. 8 and it is schematically illustrated in arelaxed condition in FIG. 14. This pattern comprises sixsided openingswhich are staggered in a vertical direction and opposite sides of eachopening are formed of two-needle walewise extending stitch chains,indicated at C in FIG. 14. The two-needle stitch chains C areinterconnected by diagonally extending single-needle stitch chainportions K.

In this particular honeycomb pattern, ten courses are required for eachrepeat of the pattern, as indicated at C-1 through C-10 on thepoint-paper layout illustrated in FIG. 15. The machine is set up so thatthe pattern cam wheels 173, 174 make one revolution while the needles 31are raised and lowered to knit ten courses. The manner in which the yarnguide rings 140, 142 are shifted relative to the needles 31 isillustrated in FIGS. 16-l9 and stitches are shown on needles 3 and 4only. To aid in the description, the needles are numbered 1-4 in FIGS.15-23.

Assuming that the needles have been lowered to knit the course C-l andthe yarns W41 have formed stitch loops on the needles 1 and 3 while theyarns W-2 have formed stitch loops on the needles 2 and 4, the partswill be in the position shown in FIG. 16. As the needles 31 raise to theupper position shown in FIG. 17, the rings 140, 142 oscillate inopposite directions a distance of one needle space. With downwardmovement of the needles 31, the rings 140, 142 shift in oppositedirections a distance of about three needle spaces so that when theneedles are about half-way down in their stroke, as shown in FIG. 18,the yarns W-Z are inclined to the left a sucient amount to be caught inthe hooks of the needles 1 and 3 while the yarns W-1 are inclined to theright a suflicient amount to be caught in the hooks of the needles 2 and4. As the needles move on down to stitch forming level (FIG. 19), theyarns W-2 form stitch loops on the needles 1 and 3 (FIG. 19) While theyarns W-1 form stitch loops on the needles 2 and 4.

Thus, the sets of yarns cross between the knitting of courses C-1 andC-2 so that the yarns W-l form stitches on the needles 1 and 3 in courseC-l and then form stitches on the needles 2 and 4 in course C-2 whilethe yarns W-2 form stitches on the needles 2 and 4 in course C-1 andthen form stitches on the needles 1 and 3 in course C-2. This crossingaction of the yarns forms the walewise extending two-needle stitch chainC with the two wales being interconnected after each stitch (FIGS. 14and 19).

During the knitting of the next courses C-3 and C-4, the guide ringsmove in the same manner but in opposite directions to continue theformation of-the twoneedle stitch chain, as illustrated in FIG. 15. Intcourses C-4 and C-5, the respective yarns W-l and `W-Z are knit on thesame corresponding needles 2, 3l` without crossing each other and theupper and lower guide rings 140, 142 are shifted or shogged in themanner illustrated in FIGS. 20-23. Knitting on the same needles incourses C-4 and C-S produces the single-needle angularly extendingstitch chains K (FIGS. 14 and 23).

Following the knitting of course C-4, the upper guide ring 140 isshifted to the right (FIG. 20) and the lower guide ring -142 is shiftedto the left. As the needles reach the top of their stroke (FIG. 21), theguide rings 140, 142 begin to move back in the opposite direction sothat they reverse positions as the needles are loweredi (FIG. 22) andthe yarn W-1 is wrapped about the needle 2 while the yarn W-2 is'reversely wrapped about the needle 3. When the needles are lowered tostitch forming position to form course C-S (FIG. 23), a stitch is againknit of yarn W-1 on needle 2 and a stitch is again knit of yarn W-Z onneedle 3 to form separate singleneedle connector stitch chains. In thecourses C`6 through C-9, the yarns W-1, W-2 are successively crossedbetween adjacent needles so that the yarns connect together thetwo-needle stitch chain formed on the needles 2 and 3 (FIG. 15). Toaccomplish this, the upper and lower guide rings 140, 142 are shifted ina manner similar to that illustrated in FIGS. 16-19; however, the yarnsare crossed between different needles; i.e., needles 2 and 3 instead ofthe needles 1, 2 and 3, 4, as was the case during the knitting ofcourses C-1 through C-3. l

As pointed out above, the guide rings 140, 142 are moved during bothupward and downward movements of the needles. Thus, the sinuous camsurfaces of the wheels 173, 174, through the corresponding followers andlinkage, impart substantially uninterrupted and continuous movement tothe guide rings while the needles are being continuously raised andlowered by means of the eccentric cam -41 so that a substantial portionof each cycle'of'movement of the needles is utilized to move the guiderings 1-40, 142 between extreme positions in each direction. Thiscontinuous and uninterrupted movement of the guide rings 140, 142 duringthe up and down movements of the needles thereby permits utilization ofthe time lag between movement of the needles between their extreme upperand lower positions and thereby permits the machine to be operated atthe high speeds heretofore mentioned.

By varying the shogging of the yarn guides and/or merely by changing thethreading of the yarns in the two yarn guide rings, it is also possibleto obtain a wide range of other different types of patterns. Forexample, a pattern referred to as a mini-square is schematically shownin FIG. 24 and in the point-paper layout of FIG. 25. In knitting thispattern, the upper and lower guide rings are each threaded one in, oneout, and a repeat is formed with each ten courses, as illustrated fromC-1 through C-10 of FIG. 25. In this knitting procedure, the yarns W-1and W-2 cooperate to form interconnected two-needle stitch chains onadjacent pairs of needles, such as needles 1, 2 and 3, 4, up throughcourse C-4. The yarns W-l, W-Z cross before course C-S so that duringcourses C-5 through C-9, the yarn W-l (which had previously knit onneedles 1, 2) then alternately knits on the needles 3, 4- and the yarnW-2 (which had previously knit on needles 3, 4) then alternately knitson the needles 1, 2. As the yarns W-1 and W-2 cross (after courses C-4and C-9), the two-needle chain stitches C are joined together byhorizontal floats at spaced apart positions, as indicated by the letterF in FIG. 24.

A regular diamond or shnet pattern is schematically illustrated in FIG.26 in the point-paper layout of FIG. 27. To form this pattern, the upperand lower guide rings are each threaded with the one in, one: outarrangement. As shown in FIG. 27, the pattern is a ten course repeat andthe guide rings successively feed their yarns W-1, W-2 to the sameneedles 1, 3 and 2, 4 to form single-needle stitch chains R throughcourse C-4. The yarns are crossed after courses C-4 and C-S to join thestitch chains formed on needles 2, 3. Stitch chains are again formed onneedles 2, 3 in courses C-6 through `C-9 and the yarns are again crossedafter courses C-9 and C-10 to join the stitch chains formed on needles1, 2 and 3, 4 so that the stitch chains are alternately joined toadjacent chains to produce the diamond configuration shown in the fabricof FIG. 26.

Many diiferent types of patterns may be knit by changing the shoggingmovements of the guide rings 140, 142. Different patterns may also beobtained merely by changing the threading of the yarns in the holes ofthe guide rings. For example, the shogging movement applied in makingthe regular diamond pattern (as shown in FIGS. 26 and 27) may also beused to make a pattern having a different appearance by simply threadingthe upper guide ring with three yarns in and one yarn out whilethreading the lower yarn guide ring one in, one out. This produces adiamond pattern with distinctive walewise stripes of heavier stitchchains and a closely spaced `zig-zag chain on each side of the heavierwale. It is also to be understood that more than two yarn guide ringsmay be utilized, if desired.

`Other attractive and unusual patterns may also be produced by feedingdifferent types or colors of yarns to the knitting machine. For example,various walewise or zig-zag stripes may be produced by feeding yarns ofdifferent colors or yarns of various sizes may be fed to the machine toform walewise extending thick and thin fabric areas. This is possible inthe present machine because of the separate yarn creel where each yarnend is withdrawn from its own supply package. Also, some stretch yarnsmay be fed while some non-stretch yarns are fed. These various threadfeeding arrangements would not be possible on machines where the warpyarns are fed from warp Ibeams.

If it is desired to form ladies stockings of the tubular open lacefabric produced on the machine, a thermoplastic stretchable multilamentyarn is preferably used and the slitting `means 50 (FIG. 6r) isdisconnected. Then, the cutting means 51 is set to cut the tube afterthe desired length is knitl and the fashioning means is controlled togradually vary the size of stitch being formed throughout the length ofeach blank. The stocking blanks are then finished in the usual mannerafter the toe end is closed, as by sewing, and the upper end is finishedby sewing or attaching a welt portion thereto.

When the blanks are to be formed into tights or leotard type garments,the slitting means 50 operates to form a slit, as shown at S in FIG. 13,at one side of the top. The lower toe ends of the blanks are closed andthe slit inner edges are joined together to form a body portion. Theinner slit edges can either be directly joined to corresponding edges ofan adjacent blank to form a single seam extending from the front edge tothe rear edge and through the crotch, or the corresponding slit edgeportions can be connected to opposite edges of a center crotch panel,not shown. In some cases, it may be desirable to provide a crotch panelwhich extends from the upper front to the upper rear of the body portionor it may extend up only a small distance in the front and rear.

The positive feed of the yarns by the shaft 60 and the positive take-upby the rolls v46, 47 provides means to accurately control the fashioningof the tubular fabric being knit. In order to more accurately controlthe feed of the yarn it may be desirable to wrap the Warp yarns twotimes around the shaft 60. The V-shaped drive grooves on the shaft 60are preferably rounded at their top and bottom portions and the angle oftravel of the incoming yarn and the yarn leaving the shaft 60 may beoffset about 20' degrees to prevent any possible overlap of the yarn asit goes onto and leaves the grooves of the positive feed shaft 60.

Whilethe present machine has been described in conjunction with theknitting of tubular fabric, it is to be understood that this machine mayalso knit iiat fabric. For example, a fiat fabric may be knit on thismachine by removing a needle and/or by threading the guide rings so thatyarn is not fed to one of the needles. In some patterns it may bedesirable to thread the yarns in such a manner that thickened selvagesare formed.

In the drawings and specification there have been set forth preferredembodiments of the invention and although specic terms are employed,they are used in a generic and descriptive sense onlly and not forpurposes of limitation, the scope of the invention being defined in theclaims:

We claim:

1. A circular warp knitting machine adaptable to knit seamless tubularfabric, said machine having a frame and comprising (a) a needle cylindersupported in a non-rotating position on said frame,

(b) needles supported for vertical movement in said cylinder,

(c) means for simultaneously raising all of said needles to yarnreceiving position and then simultaneously lowering said needles tostitch drawing level in a continuously repeating manner,

(d) yarn guide means supported above said needles and in alignment withsaid needle cylinder for guiding a separate yarn to each correspondingneedle,

(e) positive take-up means for withdrawing the knit tube at apredetermined rate,

(f) positive yarn feeding means for feeding the yarns to the needles ata predetermined rate relative to the fabric take-up rate,

(g) common drive means including variable speed means for said positivetake-up means and said positive yarn feeding means, the speed of saidcommon drive means determining the size of the knit stitch loops, and

(h) pattern means for selectively controlling said varable speed meansto thereby vary said predetermined rate of yarn feed and said fabrictake-up during the knitting of selected portions of the tubular fabric.

2. A circular warp knitting machine for knitting a continuous seamlesstubular fabric of the type suitable for forming stockings therefrom,said machine having a frame and comprising (a) a needle cylindersupported in a non-rotating position on said frame,

(b) needles supported for vertical movement in said cyflinder,

(c) means for simultaneously raising all of said needles to yarnreceiving position and then simultaneously lowering said needles tostitch drawing level in a continuously repeating manner,

(d) yarn guide means above said needles and in alignment with saidneedle cylinder for selectively guiding yarns to said needles,

(e) slitting means selectively operable at predetermined intervals tolongitudinally slit one side of the knit tube for a predeterminedllength, and

(f) severing means operated in timed relation to said machine fortransversely cutting the knit tube at intervals corresponding to theoperation of said slitting 12 means to form stocking blanks of thedesired length and having a slit extending inwardly from one end.

3. A knitting machine according to claim 2, including positive take-upmeans comprising a pair of driven takeup rolls between which the knittube is drawn, and wherein said slitting means comprises an elongateguide member positioned inside the knit tube and constrained againstmovement in the direction of movement of the knit tube by the entranceside of said take-up rolls, said guide member having a longitudinalgroove therein, a slitting blade supported adjacent said guide memberand being operable by said pattern means to move into the groove of saidguide member in timed relation to operation of said severing means tolongitudinally slit the knit tube.

4. A circular warp knitting machine comprising (a) a needle cylinderhaving needle supporting s'lots around the outer periphery thereof,

(b) needles supported for vertical lmovement in the slots of saidcylinder,

(c) means for simultaneously raising all of said needles to yarnreceiving position and then simultaneously lowering said needle tostitch drawing level in a continuously repeating manner,

(d) yarn guide means positioned above said needles and in alignment withsaid needle cylinder, said yarn guide means including at least one yarnguide ring,

(e) Vmeans supporting said yarn guide means for oscillation in ahorizontal plane to guide yarns to the needles, said support meansincluding a support member with a V-shaped groove mating with andsupportingly engaging the outer peripherall edge of said guide ring, and

(f) control means for imparting uninterrupted and continuous oscillationto said guide means during both upward and downward movements of saidneedles to thereby permit high machine operational speeds by utilizing asubstantial portion of each cycle of movement of the needles to movesaid yarn guide means between extreme positions in each direction.

5. A circular warp knitting machine according to claim 4, including aneedle actuating ring surrounding said needle cylinder and beingoperatively connected to said needles, and wherein said means (c)includes (l) a drive shaft supported in spaced relationship below thecenter of said needle cylinder,

(2) an eccentric ixed on said drive shaft,

(3) means operatively connecting said eccentric and said needleactuating ring for imparting vertical movement to said needle actuatingring and the needles operatively connected thereto, and

(4) counterweight means carried by said shaft and adjacent saideccentric for balancing the motion of the eccentric as it is rotated athigh speeds.

6. A circular warp knitting machine according to claim 4, wherein saidsupport means (e) consists of three substantially equally spaced apartsupport members.

7. A circular warp knitting machine comprising (a) a fixed needlecylinder having needle supporting slots around the outer peripherythereof,

(b) needles supported for vertical movement in the slots of saidcylinder,

(c) means for simultaneously raising all of said needles to yarnreceiving position and then simultaneously lowering said needles tostitch drawing level in a continuously repeating manner,

(d) yarn guide means positioned above said needles and in alignment withsaid needle cylinder for guiding yarns to the needles, said yarn guidemeans including at least one guide ring having inner and outerperipheral edges and yarn guide openings adjacent the inner peripheraledge thereof, the outer peripheral edge of said guide ring being beveledon both the upper and lower sides,

(e) means supporting said guide ring for oscillation in a horizontalplane, said support means consisting E three substantially equallyspaced apart support members supportingly engaging the outer peripheraledge of said guide rings, said support members each including a V-shapedgrooved portion mating with and supportingly engaging the outerperipheral edge of said guide ring,

(f) pattern control means for oscillating said yarn guide ring in timedrelationship to vertical movement of the needles.

References Cited UNITED STATES PATENTS 205,663 7/1878 McNary 66-81 XR386,272 7/1888 Sibley 66-132 XR 770,633 9/ 1904 Folsom 66--147 960,7556/ 1910 Wildman 66-147 1,005,720l 10/1911 Lawrence 66-81 1,201,80310/1916 Chace 66-195 1,524,388 1/ 1925 Campbell 66-147 1,649,126 11/1927 Ratignier 66-81 1,828,878 10/ 1931 Seifert 66--81 1,855,033 4/ 1932Spiers.

. 14 1,869,304 7/1932 Decker et al. 1,998,473 4/ 1935 Welch et al 66-82,447,103 8/ 1948 Susen 66-147 XR 670,497 3/ 1901 Hill 66-81 FOREIGNPATENTS 2,013 4/ 1946 France. 146,510 12/1881 France. 828,578 1/ 1952Germany. 12,195 1848 Great Britain. 23,650 1903 Great Britain. 985,6663/ 1965 Great Britain. 1,036,246 7/ 1966 Great Britain.

46,023 9/ 1962 Poland. 15

OTHER REFERENCES WM. CARTER REYNOLDS, Primary Examiner U.S. Cl. X.R.

